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Pipes are required for carrying fluids. These fluids can be of various states of
matter. Gaseous fluids ( like LPG ), Liquid Fluids ( like Water ) and Solid or Semi-solid
( like plastic pellets ).
The pipes in Process Industry like in Reliance are used for transferring fluids at
higher temperature and pressure.
The various processes in a Process plant cause the liquids to be pressurized and to
be heated up. Thus the liquids passing through the pipes attain a high pressure and/or a
high temperature.
When a metal is heated it expands. If this metal of pipe is allowed to expand
freely, there is no overstress in the same. But suppose the free movement is restricted by
any means, stress is introduced in the system.
The case becomes more complicated by considering weight of the pipe, the
insulation, weights of the valves, flanges and other fittings and the pressure of the fluids
that is flowing through the piping.
Piping systems are not self supporting and hence they require pipe supports to
prevent from collapsing. Pipe supports are of different types like Rest, Guides, Linestops,
Hangers, Snubbers, and Struts. Each type of pipe support plays a vital role in supporting
the pipe system. Pipe supports are desirable to reduce the weight, wind and where
possible, expansion and transient effects, so that piping system stress range is not
excessive for the anticipating cycles of operation, us avoiding fatigue failure. Limiting the
line movement at specific locations may be desirable to protect sensitive equipment, to
Pipe supports[4] are essential features of piping systems as most piping systems
can be described as irregular space frames which usually are not self supporting and
therefore they must be provided with supports to prevent sagging. The loads imposed on
the pipe must, in all cases be transmitted from pipe to the supporting structure. Limiting
the line movement at specific locations may be desirable to protect sensitive equipment,
to control vibration or to resist external influences such as wind, earthquake, or shock
loading.
Support restraints and braces are therefore desirable to reduce weight, wind and
where possible expansion and transient effects, so that the piping system stress range is
not excessive for the anticipated cycles of operation, thus avoiding fatigue failure.
Piping supports are required for the following purpose :-
• To limit the sagging of the piping system within allowable limits (Rest, Hangers)
• To limit or direct line movement at specific locations so as to protect sensitive
equipment against overheads (guides, Linestops, directional restraints)
• To control vibrations (vibration dampers)
• To resist external influences such as wind, earthquake, and shock loading
(Snubbers)
The most common types of supports used to support piping are mentioned below :-
• Gravity support – Rests, Hangers
• Thermal restraints – Guides, anchors, directional restraints
• Special purpose supports – Sway brace, vibration dampers.
• Dynamic restraints against shock, occasional loading – Snubbers.
Supports to reduce friction loadings- PTFE, Slide plates, rollers and Graphite plate.
Figure 2 - 1
2.1.2 Guide
Guide is used to support the pipe from sagging and avoid
pipe deflection in lateral direction thus restricting
downward and lateral movement of pipe. Usually 2 mm
gap is provided between guide and pipe.
Figure 2 - 2
2.1.3 Linestop
Linestop is used to support the pipe from sagging and
avoid pipe deflection in axial direction thus restricting
downward and axial movement of pipe. Usually 2 mm gap
is provided between Linestop and pipe.
Figure 2 - 3
A combination of only guide or only Linestop i.e. without any rest can be used
where as even PTFE plates can be used to reduce the friction between rest and the
ground. To restrict motion of pipe in axial as well as in lateral direction both linestop and
guide can be used simultaneously.
2.2.1 Hangers
To prevent constraints in the system, thermal
expansion in the piping and the other piping
components must not be hindered. The piping must
therefore be supported in a correspondingly elastic
manner so to compensate slight vertical
displacements in the piping, spring components are
used as supports.
Figure 2 - 4
Figure 2 - 5
These particular components act both in tension and compression and are used to
stabilize the piping and other plant components and an additional damping effect is
obtained at the same time.
2.2.3 Snubbers
Figure 2 - 6
Snubbers are installed to restrict axial or lateral movement of pipe in case of
earthquake. In normal condition snubber does not restrict axial or lateral movement of
pipe.
Operation :-
Control valves- The function of snubber is controlled by the main control valve (B),
axially mounted within the hydraulic piston (A).
During the piston movement ( ≤ 2 mm/s ) the valve is kept open by spring
pressure and hydraulic fluid flows freely from one side of the piston to the other. During
rapid piston movement ( approx. ≥ 2 mm/s ) above the speed limit, the resulting fluid
flow pressure on the valve plate closes the main valve. The flow of hydraulic fluid is
stopped and movement is blocked. The compressibility of the fluid cushion has a
softening effect on the restriction of the piston. This prevents damaging load spikes.
For movement in the compressive direction, the compensating valve (D) closes
almost synchronously with main valve.[4]
Cold spring is the process of offsetting the piping system with displacement loads
( usually accomplished by cutting short or long the pipe runs between anchors ) for the
purpose of reducing the absolute expansion load on the system. However many engineers
avoid cold spring due to the difficulty of maintaining accurate records throughout the
operating life of the unit and whereas the future analysts attempting to make field repairs
or modifications may not necessarily know about cold spring specification. Therefore
instead of cold spring expansion loops are suggested where limitation of space is not the
criteria.[5]
Cold spring is used to do the following :
• Hasten the thermal shakedown of the system in fewer operating cycles.
• Reduce the magnitude of loads on equipment and restraints, since often only a
single application of a large load is sufficient to damage these elements.
Figure 3 - 1
• It should be noted that credit cannot be taken for cold spring in the stress
calculations, since the expansion stress provisions of the piping codes require the
evaluation of the stress range, which is unaffected by cold spring. The cold spring
merely adjusts the stress mean, but not the range.
Due to the difficulty of properly installing a cold sprung system, most piping
codes recommend that only 2/3 of the specified cold spring be used for the equipment
load calculations.
When any piping isometric drawing is given for stress analysis the aim of the
stress analysis Engineer is to ensure the safety against failure of the piping system by
verifying the structural integrity against loading conditions, both external and internal
expected to occur during the lifetime of the system in the plant.
Hence the objectives of the stress analysis could be listed as :-
• Ensure that stresses in piping components in the systems are within the allowable
limits.
• Ensure the nozzle loadings are within the allowable limits.
• Ensure that sustain vertical displacement is within 10mm.
• Ensure the safety against the occasional loadings such as Seismic and wind.
• Solve dynamic problems developed due to mechanical vibrations, acoustic
vibration, fluid hammer, pulsation, relief valves etc.
The other causes of the pipe stress are the occasional loads caused due to Wind,
earthquakes, dynamic loads due to equipment operation like Reciprocating Compressor,
Pilot safety valve reaction force, Slug flow etc.
The dynamic load changes so quickly with time that the system will have no time
to distribute the load. Hence the system develops unbalanced forces.
The examples of Dynamic loadings are wind load, earthquake, fluid hammer etc.
these can be categorized in to mainly three types:-
4.3.2.1 Random :
In this type of loading the load changes unpredictably with time. The
major loads covered under this type are :-
• Wind load :
In most of the cases analysis is done using static equivalent of dynamic
model. This is achieved by increasing the static loading by a factor to account for the
dynamic effects.
• Earthquake :
Here again the analysis is done using static equivalent of a dynamic
loading model. This is again is approximate.
4.3.2.2 Harmonic :
In harmonic type of profile, the load changes in magnitude and direction in
a sine profile. The major loads covered under this are :-
• Equipment Vibration :
This is mainly caused by the eccentricity of the equipment drive shaft of
the rotating type of equipment connected to the piping.
• Acoustic Vibration :
This is mainly caused by change of fluid flow condition within pipe i.e.
from laminar to turbulent e.g. Flow through orifice. Mostly these vibrations follow
harmonic patterns with predictable frequencies based on flow conditions.
4.3.2.3 Pulsation :
This type of loading occurs due to flow from reciprocating pumps,
compressors etc. if this type of profile the loading starts from zero to some value, remains
there for certain period of time and then comes back to zero. The major types of loads
covered under this are :-
• Fluid hammer :
If the flow of fluid is suddenly stopped due to pump trip or sudden closing
of valve, there will compression of fluid at one side and relaxation at the other side. This
wave propagates causing pulsation flow.
SL = Longitudinal stress.
Fax = Internal axial force
Am = Cross sectional area = (pi/4)* ( do² - di² ) = pi * dm * t
dm = Mean diameter = (do + di )/2
Figure 4-1
Variation in bending stress through cross section of pipe is as shown. The bending
stress is zero at the neutral axis and varies linearly across the cross section from
maximum compressive to maximum tensile.
SL = Mb * c/I
Where,
Mb = Moment of the beam.
c = distance of point of interest from the neutral axis.
I = Moment of inertia
Z = Section modulus = c/I
The stress is maximum where c is greatest i.e. at the outer radius.
SL=Mb*Ro / I = Mb / Z …(4.3)
Figure 4-2
The yield stress is the elastic limit and that is the value below which the stresses
are proportional to strain and when the load is removed, there is no permanent distortion.
The tensile strength is the highest load, which the specimen can be subject to without
failure.
The code ANSI / ASME B 31.1 permits smaller of ¼ of the tensile strength or 5/8
of the yield strength. ANSI / ASME B 31.3 uses lower of 1/3 of the tensile strength or 2/3
of the yield strength.
This straining induces stress in the pipe. However when the line is cooled during
shutdown to ambient temperature the expansion returns to zero, the straining no longer
exists and hence stress also disappears. Every time the plant starts from a stress free
condition i.e. cold condition and soon gets to stressed with maximum at operating
conditions from cold get stressed with stress reaching maximum at operating condition
and then reducing to zero when operating stops and system cools down.
The actual performances of the piping system do not exactly follow the above
path. The piping system can absorb large displacement without returning to exactly to
previous configuration. Relaxation to the sustaining level of material will tend to establish
a condition of stability in few cycles, each cycle lowering the upper limit of hot stress
until a state of equilibrium is reached in which the system is completely relaxed and
capable of maintaining constant level of stress. The stress at which the material is relieved
due to relaxation appears as stress in opposite sign. Thus the system which originally was
stressless could within a few cycles accommodate stress in the cold condition and spring
itself without the application of external load. This phenomenon is called “Self
springing”. This is also called the Elastic shake down. This can be represented as shown
in the sketch below. Here the maximum stress range is set to 2 Sy or more accurately the
sum of hot and the cold yield stresses in order to ensure eventual elastic cycling.
The degree of self springing will depend upon the magnitude of the initial hot
stresses and temperature, so that while hot stresses will gradually decrease with time, the
sum of the hot and cold stress will stay the same. This sum is called the Expansion Stress
range. This concepts lead to the selection of an allowable stress range.
For materials below the creep range the allowable stresses are 62.5% of the yield
stress, so that bending stress at which plastic flow starts at elevated temperature is 1.6 Sh
and by same reasoning 1.6 Sc will be stress at which flow would take place at minimum
temperature. Hence, the sum of this could make the maximum stress the system could be
subjected to without flow occurring in either the hot or cold condition.
Therefore, Smax = 1.6(Sc+Sh)
4.5.1.2 Occasional
So = ( 0.75*i*MA / Z ) + ( 0.75*i*MB / Z ) + ( P*do / 4 t ) ≤ KSh
where,
So = Occasional stress.
MB = Resultant range of moments due to occasional loads
= ( Mx² + My² + Mz² ) 0.5
K = Occasional load factor
= 1.2 for loads occurring less than 1% of the time
= 1.15 for loads occurring less than 10% of the time.
4.5.1.3 Expansion
SE = (i Mc / Z) ≤ SA
Where,
Mc = Resultant range of moments due to Expansion (secondary)
loads
= ( Mx² + My² + Mz² ) 0.5
SA = Allowable expansion stress range
4.5.2.2 Occasional
The code states that calculate the stresses due to sustained and occasional loads
independently as per the above equation and then add them absolutely. The sum should
not exceed 1.33 Sh.
4.5.2.3 Expansion
SE = (ii Mi ² + io Mo ² + 4 MT ²) 0.5 / Z ≤ SA
where,
SE = Expansion stress range
Mi = Range of inplane bending moment due to expansion (secondary) load
Mo= range of outplane bending moment due to expansion (secondary) load
MT = Range or torsional bending moment due to expansion load
SA = Allowable stress range.
When the piping system is tested, it is not necessary to consider other occasional
loads such as wind and earthquake as occurring concurrently with test loads.
Before I discuss about the Analysis of the line let me tell you about the Expander
and the importance of the line for Fluidilized Catalytic Cracking Unit (FCCU) plant. The
line is connected between Expander inlet and 3rd Separator while the bypass line is
connected to orifice chamber. Expander is a part of Power recovery train which generates
electricity 2.5 MW.
Figure 5-1
rd
Thus Expander 3 Separator line is very important unit of FCCU. However this
line has to be analyzed again since it had faced some problems during its operation.
Companies like BECHTEL, PATHWAY PIPING SOLUTIIONS, REFINERY
TECHNOLOGY INC. (RTI) are working on the problems of this line and I too have been
given opportunity to do the analysis for the same.
1) The existing expander inlet line in the vertical section does not support
properly. The two out of four hinge expansion joints are bottomed down. The
spring support bottomed-out condition would eventually convert the spring
support device into rigid support. These spring supports were designed to
support the vertical section with movement of 32mm up from cold to hot.
2) In addition, the two constant spring support located at the tee were also to
designed to support the vertical section with movement of 94 mm up from
cold to hot, but these constant spring supports are only moving up at
approximate 60 mm.
3) The un-support piping load on the expander inlet line has created a high Axial
forces on the nozzle which will yield higher bending moment at the 3rd stage
separator’s outlet nozzle. The bending moment will eventually yield and
defect the nozzle over the period of operation. In some case, the refractory in
the nozzle would crack and create a hot spot on the nozzle. RTI has
experienced these conditions and recommends that Reliance should check this
nozzle internally as well as externally to insure the reliability of the expander
inlet line.
4) RTI notices that the floating support assembly were made by carbon steel
ASTM A516 Gr.7 except 24ӯ trunnions and the reinforcing pads that welded
to the pipe. These floating rings are insulated may reach the piping
temperature ( 714º C / 742º C ) due to heat transfer. Reliance needs to check
the deformation of the floating rings to assure the functioning of this support
assembly. RTI recommends that Reliance redesigns the floating rings
assemble with all material match pipe material ( stainless steel ) to assure the
safety and reliability of the expander inlet line.
Before we move on to the CAESAR results lets check the feasibility of the
software.
7.1 Considering a Cantilever pipe and calculating stresses due to self
weight and weight of water and comparing with CAESAR Output
Given :-
7.1.1 Solution :-
SA = Allowable stress range = f ( 1.25 Sc + 0.25 Sh )
= 1.0 ( 1.25 * 137.9 + 0.25 * 116.4 )
…..( where f = 1.0 for 7000 load cycles )
SA = 201.5 N/mm² …(7.1)
W2 = Weight of water
= Density of water * Volume of water in pipe * 9.81
= 1000 * { ( pi/4) * ( Di²) } * L * 9.81
= 1000 * { ( pi/4) * ( 0.25451 ²) } * 3.5 * 9.81
W2= 1746.8 N …(7.3)
Therefore,
Total weight, W = Weight of pipe (W1) + Weight of water (W2)
= 2066 + 1746.8
W = 3812.8 N …(7.4)
Therefore,
Shear force, Fs = 3812.8 N
Therefore, Di = Do – 2 * t
= 273.05 – 2 * 7.671
Di = 257.71 mm
2) Bending stress = Mb / Z
Now,
Section Modulus, Z = {pi* (Do4- Di4)} / (32*Do)
= {pi* (0.273054- 0.2757714)} / (32*0.27305)
= 0.000412677 m³
Z = 412677 mm³ …(7.7)
Therefore from eqn.(7.5) & (7.7),
Bending Stress = (6672.4 * 10³ / 412677 )
Bending Stress = 16.16 N/mm² …(7.8)
where as CAESAR output gives Bending stress = 16.16 N/mm²
Thus it is seen that the result obtained by CAESAR and manual calculation
are nearly same.
Figure 7-1
Figure 7-2
Figure 7-3
Given :-
Leg 10-30 Length, L = 7500 mm
O.D. of pipe, Do = 275.05 mm
Thickness of pipe, t = 9.271 mm
Corrosion allowance, C.A = 1.6 mm
Design Temperature T1 = 350 ºC
7.2.1 Solution :-
SA = Allowable stress range = f ( 1.25 Sc + 0.25 Sh )
= 1.0 ( 1.25 * 137.9 + 0.25 * 116.4 )
…..( where f = 1.0 for 7000 load cycles )
SA = 201.5 N/mm² …(7.15)
According to assumptions 3 and 4 the individual legs absorb the following portion of
the thermal expansion in X-direction :
δx = ( L³ . ∆x ) / ∑( L³ - Lx³ ) …(7.19)
where,
δx = lateral deflection in the X-direction for the leg under
consideration, mm.
L = length of the leg in question, m.
∆x = overall thermal expansion of system in x-direction, mm.
∑(L³-Lx³) = sum of cubed length of all legs perpendicular to the direction
considered.
∑(L³-Lx³) = 4 ³ = 64 m³
∑(L³-Ly³) = 3.5 ³ = 42.875 m³
As the leg 10- 20 is in horizontal X direction therefore its lateral direction will be in Y
direction.
Now as per eqn. (7.19) we have,
δy = ( L³ . ∆y ) / ∑( L³ - Ly³ )
= ( 3.5 ³ * 17.240 ) / ( 3.5 ³ )
δy = 17.24 mm = δm ...(7.20)
where δm is largest of component deflections δx, δy or δz as per eqn. (7.19)
Now calculating,
{ 39.512 * L ( SA ) } / 10 ³
= { 39.512 * 3.5* ( 201.5 ) } / 10 ³ = 1.963 ≈ 2 …(7.21)
From graph 1 and referring the above value we find out δ
Therefore,
SE = ( 203391 * 273.05 * 15.242 ) / ( 48 * 6970 * 4.0 ² )
SE= 158.10 N/mm² …(7.26)
It is seen that value obtained by eqn. (7.25) is much nearer to CAESAR value.
Therefore considering SE = 147.06 N/mm²
Now Force F,
7.2.4.2 F = Mb / L
Where,
F = Force acting on the pipe, N
Mb = Moment of pipe, N-m
L = Length of the pipe on which moment is acting, m
Therefore,
F = 60688.28 / 3.5
F = 17339.51 N ...(7.29)
According to CAESAR,
Shear force acting on node 10 and 20 = 16362 N
Bending moment at node 10 = 57267.3 N-m
Thus it is seen that the answers are close to the CAESAR output and we can
solve simple problems by manual calculation but as the pipe line goes on changing
directions and as the length goes on increasing the more difficult it becomes to solve
the same problem manually. So in such cases only the Deflection of the pipe is
calculated if done manually.
Figure 7-6
Figure 7-7
Figure 7-8
D3 – Displacement of Expander when expander inlet line and bypass are on and at
design temperature.
D4 – Displacement of Expander when expander inlet line and bypass are on and at
operating temperature.
H – Hanger loads
CS – Cold spring case
WIN1 – Wind blowing in north direction (i.e. –ve X direction)
WIN2 – Wind blowing in south direction (i.e. +ve X direction)
WIN3 – Wind blowing in east direction (i.e. -ve Z direction)
WIN4 – Wind blowing in west direction (i.e. +ve Z direction)
U1 – Seismic in North-south direction
U1 – Seismic in East-west direction
Table 8-1
9.2 DISPLACEMENTS
9.2.1 Displacement due to Sustain
In Sustain only Y displacement is checked. It is found that the maximum Y
displacement = - 43.258 mm at node 2804 for both sustain cases i.e. considering Pressure
P1 and Pressure P2 respectively. Node 2804 is on the vertical section of the Expander
inlet line and 3rd Separator. It is clear that the springs at that section are not taking the
total load and thus the line is sagging downwards. Refer Table 9-4, 9-5 for more detail.
Even the RTI has marked error for the springs at the Tee (see point 2 of page 24).
Thus by providing more support at the vertical section the sustain displacement can be
brought under control but the Piping layout Engineer has to be asked for available space
and available column for hanging springs in case if used.
Target will be to reduce the Sustain Y displacement below 10 mm.
9.2.2.1 T1 case,
Max. X = -92.381 mm at Node 226 Max. Z = -363.564 mm at Node 55
As the bypass line is off the Max Z direction is seen at node 55 which is on
vertical line of expander which shows the axial displacement of the expander inlet line.
Max X is seen at node 226 which is on the bypass line. Refer Table 9-6, Table 9-7 for
details.
9.2.2.2 T2 case,
Max. X = 191.168 mm at Node 3700 Max. Z = 158.243 mm at Node 20000
As the expander inlet line is off the Max Z direction is seen at node 20000 which
is on the bypass line which shows the axial displacement of the bypass line. Max X is
seen at node 3700 which is on the bypass line and shows the lateral deflection. Refer
Table 9-8, Table 9-9 for details.
9.2.2.3 T3 case,
Max. X = 191.168 mm at Node 3700 Max. Z = -363.482 mm at Node 55
As the bypass line and the expander line both are on and working at design
temperature the Max Z direction is seen at node 55 which is on vertical line of expander
which shows the axial displacement of the expander inlet line. Max X is seen at node
3700 which is on the bypass line. Refer Table 9-10, Table 9-11 for details.
9.2.2.4 T4 case,
Max. X = 185.486 mm at Node 3700 Max. Z = -348.253 mm at Node 55
Similarly as the bypass line and the expander line both are on and working at
operating temperature the Max Z direction is seen at node 55 which is on vertical line of
expander which shows the axial displacement of the expander inlet line. Max X is seen at
node 3700 which is on the bypass line. Refer Table 9-12, Table 9-13 for details.
Seeing the result it is very clear that the Expander inlet line is not very safe. The
analysis has to be done to revise the spring load or may even require more springs,
supports so that the line becomes safer. As each of the above cases are interlinked with
each other final analysis will show whether the nozzle load will come under allowable or
will exceed more.
Now as our nozzle is inclined to Y and Z direction therefore resultant Force and
Moment is checked at NODE 1:-
Obtained MR = ( MY ² + MZ ² )0.5
= (177093 ² + 456483 ² )0.5
= 489724.38 N-m < Allowable MR
Obtained FA = ( FY ² + FZ ² )0.5
= (189311 ² + 8687 ² )0.5
= 189510.21 N < 80 % of Allowable MR
Thus Axial Force has to be reduced for safer operation. This problem has been
also marked by the RTI in their report (see point (3), page 24). Thus analysis of this has
given a confirmation to their study.
We have,
Longitudinal Bending Moment ML,
ML = β * 0.13 * D²
= 0.8 * 0.13 * 66 ²
= 453.024 kNm = 453024 N-m
Bypass line is not scope of my project but I have to consider it since any change in
loads or supports will indirectly or directly affect the Bypass Nozzle.
Obtained ML = ( MX ² + MZ ² )0.5
= (28110 ² + 1523896 ² )0.5
= 1524155.24 N-m < 240 % of Allowable ML
Obtained MC = MY
= 72486 N-m < Allowable MC
Obtained MR = ( ML ² + MC ² )0.5
= (1524155.24 ² + 72486 ² )0.5
= 1525877.92 N-m < 170% of Allowable MR
Obtained FA = FY
= 226275 N < 115% of Allowable FA
Table 9-15 : Nozzle load checked for Node 345 and 1000
10.2 DISPLACEMENTS
10.2.1 Displacement due to Sustain
In Sustain only Y displacement is checked. It is found that the maximum Y
displacement = 19.750 mm at node 11584 for both sustain cases i.e. considering Pressure
P1 and Pressure P2 respectively. This is due to Bottom spring near that point and line is
not completely modeled as that line is not in the scope of project. Therefore neglecting
that line we found that,
Max. Y displacement = -5.702 mm at node 220.
In sustain case the Maximum Y displacement should not be more than 10 mm
which is achieved here. It was clear that the springs at that section are not taking the total
load and thus the line is sagging downwards so to by revising the spring loads and
designing new springs at Node 1801, 1802, 2001 and 2002 the displacement was brought
under control. Spring at Node 18 and Node 200 were replaced by above springs.
NODE PRESENT spring load MODIFIED spring load
18 130274 N -
200 130274 N -
1801 - 134500 N
1802 - 134500 N
2001 - 70000 N
2002 - 70000 N
20000 82328 N -
20001 82328 N -
216 - 64180 N
4001 50939 N 62000 N and spring rate 533 N/mm
4002 50939 N 62000 N and spring rate 533 N/mm
4003 50939 N 62000 N and spring rate 533 N/mm
4004 50939 N 62000 N and spring rate 533 N/mm
In present line springs are placed at Node 18 and 200 which are on the Tee section
of the line. These two springs were not sufficient to take the load of the vertical section so
instead of 2 springs the modified line is having 4 springs i.e. 1801, 1802, 2001 and 2002.
As the load of the pipe is reduced the two springs at Node 20000 and 20001 were
replaced by single spring at Node 216. As the vertical displacement were reduced the
constant springs at 4001, 4002, 4003 and 4004 are replaced by variable springs.
10.2.2.1 T1 case,
Max. X = -96.491 mm at Node 220 Max. Z = -364.668 mm at Node 55
As the bypass line is off the Max Z direction is seen at node 55 which is on
vertical line of expander which shows the axial displacement of the expander inlet line.
Max X is seen at node 220 which is on the bypass line. Refer Table 10-8 for detail.
10.2.2.2 T2 case,
Max. X = 148.625 mm at Node 216 Max. Z = 153.926 mm at Node 2804
As the expander inlet line is off the Max Z direction is seen at node 2804 which is
on the bypass line which shows the axial displacement of the bypass line. Max X is seen
at node 216 which is on the bypass line and shows the lateral deflection. Refer Table
10-9, 10-10 for detail.
10.2.2.3 T3 case,
Max. X = 153.937 mm at Node 2804 Max. Z = -364.668mm at Node 55
As the bypass line and the expander line both are on and working at design
temperature the Max Z direction is seen at node 55 which is on vertical line of expander
which shows the axial displacement of the expander inlet line. Max X is seen at node
2804 which is on the bypass line. Refer Table 10-11, 10-12 for detail.
10.2.2.4 T4 case,
Max. X = 147.525 mm at Node 2804 Max. Z = -349.362 mm at Node 55
Similarly as the bypass line and the expander line both are on and working at
operating temperature the Max Z direction is seen at node 55 which is on vertical line of
expander which shows the axial displacement of the expander inlet line. Max X is seen at
node 2804 which is on the bypass line. Refer Table 10-13, 10-14 for detail.
In present line the Moment MY was 8983 N-m which was more than allowable.
Actually this moment has decreased by changes in spring loads near the nozzle. As there
is no space for any new changes I could only change spring loads at Node 9711 and 9712.
In present analysis the obtained MR = 489724.38 N-m which was more due to
larger value of MZ. MZ in Modified analysis is reduced by reducing forces FX and FY.
Obtained FA = ( FY ² + FZ ² )0.5
= (127128 ² + 7438 ² ) 0.5
= 127345.41 N < 21 % of Allowable MR
Earlier FA was 189510.21 N which was less than 80 % of Allowable MR.
Axial force on the nozzle was reduced by using 4 springs at Node 1801, 1802,
2001 and 2002 instead of only springs at Node 18 and 200.
CONCULSION
Usually results obtained by stress analysis may differ from analyst to analyst since
there are number of ways of reducing the loads of pipe. However results obtained by
making least changes is said as the best Analysis since this will reduce the cost of the
manufacturing, will require lesser space and will require lesser maintenance.
Therefore the best analyst always tries to find solution by making least changes. In
my project I was aware of the congestion of space and the problems faced by the line
which guided me to find a solution. As very less ground support is available the whole
analysis was done on the basis of hangers and they were used to reduce the nozzle loads
which made the line safer.
My objectives of the project were :-
1. Finding out the deviations if any
2. Analyzing the deviations.
3. Finding out acceptability level of deviations.
4. Suggest recommendation for improving unit reliability.
BIBLIOGARPHY
[1]. The M.W.Kellogg Company “ Design of Piping Systems, ” revised second edition:
John Wiley & Sons, INC. -1967.
[2]. John Mcketta “ Piping design Handbook, ”: Marcel Dekker, INC.- 1992.
[3] “ Quick check on piping flexibility, ” : L.C.Peng, Peng Engineering, Houston, Texas.
[4]. LISEGA “ Standard Supports 2010, ” edition October : Rosebrock Media Service,
Sottrum – 2001.
[5]. CAESAR 2 version 4.5 “ Technical reference manual ” : C.A.E Engineering software
- 2002.
[6]. “Allowable Forces and Moments ”: 3PS_MV001, Bechtel Standard.
[7]. Mohinder L.Nayyar “ Piping Handbook, ”: seventh edition : McGraw – Hill
handbooks.
[8]. ASME B 31.3 “ Petrochemicals and Refinery Piping or Process Piping, ”: 2002
edition
[9]. “ Pipe stress analysis ” : R.V.Balapure, Reliance Engineering Associates Limited,
India.
[10]. S.Ramamurtham, “ Strength of Materials, ” - Dhanpatrai & Sons,Delhi,1990.